Cable Collet Alignment for Misshaped End Component Assembly
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Solution Overview
Problem
The insertion of components like shielding ferrules and seals on cables is inefficient due to low productivity and the difficulty in aligning misshaped cable ends, requiring manual manipulation and reshaping.
Innovation Solution
A collet mechanism with an expandable portion and resilient legs that moves between closed and expanded positions to securely position and align components on cables, reshaping the cable end for easy component insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual insertion of components is used, then flexibility in handling misshaped cable ends is improved, but productivity is reduced
Solution Approach 1:
The patent introduces a collet as an intermediary tool that holds the component and guides it onto the cable. The collet includes a cable receiving opening that can accommodate misshaped cable ends, and resilient legs that apply controlled pressure to reshape and secure the cable end during automated insertion, eliminating the need for manual manipulation while maintaining ease of operation
Solution Approach 2:
The patent replaces the manual mechanical manipulation of cable ends with an automated mechanical system consisting of a collet with resilient legs. The resilient legs automatically apply pressure to reshape misshaped cable ends and secure components during the insertion process, substituting manual operations with automated mechanical action that maintains flexibility while improving productivity
2Productivity
If automated insertion is implemented, then productivity is improved, but the ability to handle misshaped cable ends is reduced
Solution Approach 1:
The patent employs a dynamic collet with resilient legs that can adapt their shape and pressure application during the automated insertion process. The resilient legs flex to accommodate misshaped cable ends and apply controlled pressure to reshape them, allowing the automated system to dynamically adapt to variations in cable end geometry while maintaining high productivity
Solution Approach 2:
The patent changes the physical parameters of the cable end interaction by using resilient legs that apply controlled pressure and force during insertion. The resilient legs can deform and apply varying pressures to reshape misshaped cable ends, allowing the automated system to handle a range of cable end geometries by dynamically adjusting the mechanical parameters of the insertion process
3Adaptability or versatility
If component insertion is manual, then adaptability to misshaped cables is improved, but manufacturing precision is reduced
Solution Approach 1:
The collet acts as a precision intermediary tool that holds the component in a fixed, precise position while guiding it onto the cable. The cable receiving opening and resilient legs work together to precisely position and secure the cable end, ensuring accurate component placement even when the cable end is misshaped, thereby maintaining manufacturing precision while adapting to cable variations
4Manufacturing precision
If automated collet mechanism is used, then manufacturing precision is improved, but device complexity is increased
Solution Approach 1:
The collet mechanism is segmented into distinct functional components: the collet body with cable receiving opening, multiple independent resilient legs, and component holding features. This segmentation allows each element to perform its specific function (cable reception, reshaping, securing, component positioning) independently, simplifying the overall design and manufacturing while maintaining precision
Solution Approach 2:
The resilient legs are designed to automatically perform multiple functions: they flex to accommodate misshaped cable ends, apply controlled pressure to reshape the cable, and secure both the cable and component in precise positions. This self-service capability reduces the need for additional complex mechanisms, controlling device complexity while maintaining manufacturing precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances productivity by automating the component insertion process, ensuring accurate alignment and secure attachment of components on cables, even when ends are misshaped, improving efficiency and ease of use.
Implementation Method 1
The resilient legs have fixed ends and free ends. Slots are provided between the resilient legs. The slots separate the resilient legs to allow each resilient leg to act independently of the other resilient legs. The expandable portion is movable between a closed position, in which the resilient legs have a first outside diameter, and an expanded position, in which the resilient legs have a second outside diameter
Data Source
AI summary
A method of positioning a component on a cable. The method includes: moving a collet into position on the component; engaging the component with the collet; moving the collet with the component positioned thereon into alignment with an end of the cable; securing the collet to the end of the cable; moving the component from the collet to the cable; and removing the collet from the end of the cable.